red_smeg

Hi

I recently started getting small foam like material being spat out of my aircon system outlets.

I have a 2005 997. Is this normal with age is there a reasonably cheap way to fix this.

PhilD

Is it black foam? If so most probably the foam seals have broken down on the ducts and doors, and is flying out the vents. You could dissemble the duct work and replace the foam seals, if they are even available, or you could just wait until it stops blowing out and live with the fact the AC system maybe marginally less effective.

Luckymba

Had exactly the same issue last month and posted about it. Pretty good input. I turn it on high, cycle through the vents and let it blow out then shop vac it out. Honestly it is still coming out but in much smaller quantities. Based on the responses I have no plans to do anything about it other than vacuum it us so it doesn't grind into my carpet. I also have a 2005.
https://rennlist.com/forums/997-foru...air-vents.html

Ben Z

'05 here also, had the same thing going on a few months ago. I ran the blower on high periodically to hasten the process, and kept a long tweezer in the glovebox to pick out the chunks that got stuck, now I haven't had any come out in months. A couple people said oh it's going to cause all sorts of probs and to get it fixed, but the dealer said the only way to fix it would be to take the dash apart and change the airbox, but that if I don't, nothing bad will happen and I won't notice any loss of A/C performance. He said to wait until and unless the A/C goes bad and then put it through my extended warranty. It's south Florida here, hot and humid most of the year, and indeed I have not noticed any loss of cooling performance or any other issues. So it's messy (the pieces are kind of gooey and will leave residue on your clothes) for a short time but the problem is self-limiting.

Luckymba

Red where do you live (where was car from)? Like Ben I'm in Florida - car has been here most of its life. Probably heat and humidity accelerate the process.

Cbst09

Is this an issue with all of the 997s or just those from 05? I'm wondering if it's just happening to the 05s now and something I can look forward to happening with mine in a few years.

red_smeg

I Live in Boca Raton, FL. Car has always been in FL.

red_smeg

Yeah You are 100% correct its is that type of foam

jrosa55

Happening to my 1999 C2 also.

MarcoRemius

Happened in my '96 VW. SUPER annoying.

GermanCarSpecialists

Porsche's solution is to replace the a/c. We do a lot of these. However we do not replace the boxes. We remove the complete box assembly out of the car. Clean the foam from the door cards, and replace them with another material. Reassemble the a/c box.

We see this more often on cars with low miles.

Dirtmerchant

Not just a Porsche issue, I have an 05 Lexus LX and 06 Lexus GS and both of them are shedding foam too.

Lance-AR

I seem to recall seeing a total of around 20 hours labor to disassemble the dash and scrap clean the flap with the deteriorating foam. My 05 has been blowing junk since January and it was only bad for a few months

Luckymba

I just turned my ac on high and waited with a shopvac. Ran for about a minute then vacuumed. Cycled through that about 5 times. Did the same with the heat. Haven't had an issue since.

OKB

had this issue with alot of 928s. Took apart the entire air box and all the origional foam was dissintegrated. Removed it all and replaced with vinyl type foam which is solid rather than open air cells This may be the fix but not very feasable for most people to do